In the age of Industry 4.0, where more customers look for personalized products, the enterprises must keep pace with smart manufacturing to outperform the competitive global market.

At ShanghaiTex 2019, leading global manufacturers showcased their exhibit highlights and shared their insights on smart manufacturing.

At the show, Rieter Components, along with the components manufacturers within the Group, including Bräcker, Graf, Novibra, SSM and Suessen, presented their comprehensive solutions at the booth.

SSM’s precision package winder PWX.

Suessen’s EliTe is a versatile compact-spinning system with new components.

Huang Wei, Head of Big Contract Management China, Business Group Machine & System China, Rieter (China) Textile Instruments Co., Ltd. and Steven Lin, Sales Director China, SSM Schärer Schweiter Mettler AG, accepted an exclusive interview with CTA.

(Left) Huang Wei, Head of Big Contract Management China, Business Group Machine & System China, Rieter (China) Textile Instruments Co., Ltd.; Thomas Elsener, Marketing Service, SSM Schärer Schweiter Mettler AG; and Steven Lin, Sales Director China, SSM Schärer Schweiter Mettler AG.

Commenting on the market development, Huang Wei said: “The cotton spinning industry emphasizes heavily on digitization and automation. The purpose is to reduce labor, cut costs and save energy.”

Huang Wei pointed out that the strong demand for automation is mainly due to the labor issue. "First of all, customers want to greatly reduce labor and to cut cost. Secondly, automation ensures consistent product quality because it is not affected by the quality of workers."

Steven Lin commented that SSM places great emphasis on fully automated machines. “SSM has been deploying automation since 20 years ago. But at that time, automation was only applied in certain processes, such as winding.”

"However, the customer’s requirements nowadays are higher, spanning from the automation of logistics, from the filling of raw materials to the transportation of final products, etc. Therefore, we are dedicated to working on this direction and pursuing full automation,” Steven Lin said.

In terms of digitalization, Huang Wei said, Rieter presented ESSENTIAL – Rieter Digital Spinning Suite. The Rieter Digital Spinning Suite provides key performance indicators and visualizes improvements for the entire spinning process.

It integrates Rieter’s digital offerings, provides customized interfaces to ERP systems and connects third-party machines and all auxiliaries that influence the production of yarn. From mid-2019, the existing Rieter digital system UPtime has also been migrated to the Digital Spinning Suite.

“Data collection is very important. Through data analytics, the digital offerings identify deviations including causes and indicate potential future errors or even failures, hence enhancing the plant management,” said Huang Wei.

He explained: “With comprehensive and clearly arranged digital analytics, this mill management system supports the management in real-time in order to strengthen the expertise of mill staff, eliminate inefficiencies and optimize costs.”

“ESSENTIALpredict applies machine learning algorithms to sensor data and compares the running behavior of similar machine types. As soon as a machine starts behaving abnormally, the user receives a message containing clear instructions from Rieter on how to avoid a potential outage. I believe self-adjusting system will be the future development direction,” he said.

At its booth, SETEX introduced the new C390 machine controller series to visitors. The controllers are equipped with essential technologies and properties for applications in Industry 4.0 environments.

The booth of SETEX was highlighted with the theme of Industry 4.0.

Available in a variety of display sizes, the controllers are designed for a wide range of coverage from data acquisition terminal to machine control and plant navigator.

Split-screen features and IP-camera connection provide a clear overview of all machines and systems, suitable for operating stenter frames and washing lines.

Meanwhile, all-new infographic and animations with intuitive swipe and scrolling gestures provide unbeatable ergonomic comfort. 

Integrated mobile connectivity turns every C390 controller into an IIoT-device with access by mobile device as well as web browser without additional app installation.

In addition, an integrated OPC UA client allows for a simple linking to finishing machines to provide all new features and the integration with SETEX OrgaTEX MES to third party PLCs.

The new SETEX C390 machine controller.

SANTEX RIMAR GROUP showcased its new version of DECOFAST 3.5 at ShanghaiTex 2019. It is the result of an evolution of continuous decatizing process under pressure, aiming to provide a reliable and effective tool for modern finishers.

This latest version is re-engineered and carries new innovations in many aspects, including mechanical, electrical and electronic, and configurations. As introduced, the working pressure and productivity of the machine are increased with same energy consumption.

In particular, the electronic parts and software are renewed with drive motors of high precision performances. The electrical components are reliable, maintenance and parts substitution simplified.

Simon Rancan, Group CEO of SANTEX RIMAR GROUP, remarked that the upgrade of the electrical and electronic parts of the machine facilitates a better data transfer for implementing Industry 4.0 workflow across the production line.

“The goal of the Industry 4.0 is to help producers to better control their production processes. We therefore make machines in our whole portfolio Industry 4.0 ready as it is beneficial to our customers,” he said.

The new version of DECOFAST 3.5 showcased at ShanghaiTex 2019.

The new DECOFAST 3.5 is manufactured by Sperotto Rimar, a brand of SANTEX RIMAR GROUP. It demonstrates the Group’s strategy in adding products for some processes closed to the processes in which the Group has been providing solutions for.

“The aim is to strengthen our position as one-stop solution provider in the industry,” Simon Rancan explained. “Besides, customers can enjoy simpler operations when using machines from the same supplier.”

Another highlighted exhibit of SANTEX RIMAR GROUP at the show was the VELURA Raising Machine for raising any fabric type.

The machine is equipped with high quality driving belts for the raising rollers drive, which are more flexible and durable compared to bigger size belts.

Five driving belts are provided to ensure a full grip on the pulley and the maximum possible energy transmission for a more efficient raising effect.

The VELURA Raising Machine is manufactured by Sperotto Rimar, a brand of SANTEX RIMAR GROUP.

According to the CEO, the Group is planning to further explore the Chinese market by expanding its product lines with new products.

“Our operation in China is performing well and business is stable. We are happy with that as many manufacturers experience 20-30% decrease in sales amidst the market slowdown,” mentioned Simon Rancan.

Simon Rancan, Group CEO of SANTEX RIMAR GROUP.

Simon Rancan pinpointed that this is due to the fact that Chinese producers have been shifting their attention to the payback of their investment instead of the selling price of the machines. They are buying more hi-end and high quality machines.

He also emphasized that the Chinese producers are upgrading their technologies for the benefits of higher productivity as well as lower energy consumption. Besides digitalization and automation, they are taking big steps towards sustainable production.

“We see a lot of Chinese producers are paying attention to sustainability. One of the reasons is the end-consumers are pushing them,” he added. “This emerging trend in China favours us as our machines are designed to maximum the output with less energy consumption.”